One-step to prepare high-performance gas diffusion layer (GDL) with three different functional layers for proton exchange membrane fuel cells (PEMFCs)

Gas diffusion layer (GDL) is one of the most important components of fuel cells. In order to improve the fuel cell performance, GDL has developed from single layer to dual layers, and then to multiple layers. However, dual or multi layers in GDL are usually prepared by layer-by-layer methods, which cost too much time, energy, and resources. In this work, we successfully developed a facile one-step method to prepare a GDL with three functional layers by utilizing the different sedimentation rates and filtration rates of short carbon fiber (CF) and carbon nanotube (CNT). The treatment temperature for this GDL is much lower than that of traditional method. The thickness of the GDL can be effectively controlled from as thin as 50 μm to more than 200 μm by simply adjusting the content of CF. The GDL with high flexibility is suitable to develop high performance flexible electronics. The fuel cell with the GDL has the maximum power density 1021 mW cm^?2, which shows 19% improvement comparing to the conventional one. Therefore, this work breaks the traditional concept that GDL for fuel cells only can be prepared by very complex and high-cost procedure.     

Multi-skeletal PtPdNi nanodendrites as efficient electrocatalyst with high activity and durability towards oxygen reduction reaction

Engineering alloy nanostructures with a combination of highly active noble metals (Pt and Pd) and less electronegative non-noble metal (Ni) is found to be crucial for improving surface reactivity by enriching with active Pt sites. Herein, a multi-skeletal PtPdNi nanodendrites (NDs) was successfully formed by a simple one-pot method with structure directing agent. The modification of Pt electronic structure and their interaction due to compressive strain were explored using benchmark characterization techniques, which showed that the PtPdNi NDs possess Pt-enriched surface, corroborating to more active catalyst sites for oxygen reduction reaction (ORR) in acidic medium. The PtPdNi NDs have a higher electrochemical surface area (63 m² g^?1) and an earlier onset potential (1.01 V) than PtPd NDs, PtNi NDs, and commercial Pt/C catalysts, indicating the outstanding ORR performance. The high mass and specific activities, as well as superior durability after accelerated degradation test (ADT), highlight the remarkable electrocatalytic performance of PtPdNi NDs over others. As a result, enhancing Pt utilization through the formation of PtPdNi NDs could be a reliable strategy to improve ORR electrocatalysis for polymer electrolyte membrane fuel cell (PEMFC) applications.     

Investigation of corrosion properties with Ni–P/TiNO coating on aluminum alloy bipolar plates in proton exchange membrane fuel cell

Aluminum alloy bipolar plates have unique application potential in proton exchange membrane fuel cell (PEMFC) due to the characteristics of lightweight and low cost. However, extreme susceptibility to corrosion in PEMFC operation condition limits the application. To promote the corrosion resistance of aluminum alloy bipolar plates, a Ni–P/TiNO coating was prepared by electroless plating and closed field unbalanced magnetron sputter ion plating (CFUMSIP) technology on the 6061 Al substrate. The research results show that Ni–P interlayer improves the deposition effect of TiNO outer layer and increase the content of TiN and TiO_xN_y phases. Compared to Ni–P and TiNO single-layer coatings, the Ni–P/TiNO coating samples exhibited the lowest current density value of (1.10 ± 0.02) × 10^?6 A·cm^?2 in simulated PEMFC cathode environment. Additionally, potential cyclic polarization measurements were carried out aiming to evaluate the durability of the aluminum alloy bipolar plate during the PEMFC start-up/shut-up process. The results illustrate that the Ni–P/TiNO coating samples exhibit excellent stability and corrosion resistance.     

Optimization and efficiency analysis of methanol SOFC-PEMFC hybrid system

In order to improve the power generation efficiency of fuel cell systems employing liquid fuels, a hybrid system consisting of solid oxide fuel cell (SOFC) and proton exchange membrane fuel cell (PEMFC) is proposed. Utilize the high temperature heat generated by SOFC to reform as much methanol as possible to improve the overall energy efficiency of the system. When SOFC has a stable output of 100 kW, the amount of hydrogen after reforming is changed by changing the methanol flow rate. Three hybrid systems are proposed to compare and select the best system process suitable for different situations. The results show that the combined combustion system has the highest power generation, which can reach 350 kW and the total electrical efficiency is 57%. When the power of the tail gas preheating system is 160 kW, the electrical efficiency can reach 75%. The PEM water preheating system has the most balanced performance, with the electric power of 300 kW and the efficiency of 66%.     

Effect of the doping time of the 1‐butyl‐3‐methylimidazolium ionic liquid cation on the Nafion membrane proprieties

Nafion membranes were prepared by incorporating in the polymer matrix the 1‐butyl‐3‐methylimidazolium (BMI⁺) ionic liquid cation at different doping levels. Increasing the doping time of the membranes with the ionic liquid results in increased incorporation of the BMI⁺ cation but a decrease in the bulk conductivity. The thermogravimetric analysis shows that the BMI⁺ cation incorporation increases the thermal stability of the membranes. The higher discharge efficiency of the fuel cell at 80°C was obtained by using Nafion membrane after 15 minutes of doping in the ionic liquid solution.     

Exergy analysis of the diesel pre-reforming solid oxide fuel cell system with anode off-gas recycling in the SchIBZ project. Part I: Modeling and validation

Solid oxide fuel cell (SOFC) systems with anode off-gas recirculation (AGR) and diesel pre-reforming are advantageous because they can operate with the current fuel infrastructure. In the SchIBZ-project, the prototype of such a SOFC system for maritime applications has already been commissioned. In this first paper, we model the system devices to conduct an exergy analysis of this real SOFC plant and validate them with experimental values from experiments in laboratory scale. The results of our simulation agree well with the experimental values. The calculations with the validated results may be closer to the real thermodynamic behavior of such system components than previous literature.     

A numerical study on the performance of PEMFC with wedge-shaped fins in the cathode channel

The gas flow field design has a significant influence on the overall performance of a proton exchange membrane fuel cell (PEMFC). A single-channel PEMFC with wedge-shaped fins in the cathode channel was proposed, and the effects of fin parameters such as volume (0.5 mm³, 1.0 mm³, and 1.5 mm³), number (3, 5, and 9), and porosity of the gas diffusion layer (GDL) (0.2, 0.4, 0.6, and 0.8) on the performance of PEMFC were numerically examined based on the growth rate of power density (GRPD) and polarization curve. It was shown that wedge-shaped fins could effectively improve the PEMFC performance. With an increase in fin volume, the distributions of oxygen mass fraction in the outlet area of the cathode channel were lower, the drainage effect of the PEMFC improved, and GRPD also increased accordingly. Similar results were obtained as the number of fins increased. The GDL porosity had a greater effect than the wedge-shaped fins on the improvement in PEMFC performance, but the influence of GDL porosity weakened and the GRPD of porosity decreased as the porosity increased. This study provides an effective guideline for the optimization of the cathode channel in a PEMFC.     

Performance investigation on a coaxial-nozzle ejector for PEMFC hydrogen recirculation system

The ejector driven by the high-pressure gas potential energy from the hydrogen storage tank can reliably recirculate the unconsumed hydrogen in the proton exchange membrane fuel cell (PEMFC) system. However, the fixed-geometry ejector cannot maintain consistently high performance among the whole power output range in the PEMFC system due to its shortage of limited operating range. In this paper, a coaxial two-nozzle ejector, satisfying the requirements of the PEMFC system under different power outputs, is developed for hydrogen recirculation. The proposed ejector is investigated numerically based on an experimentally verified simulation model to reveal the flow distribution and predict its performance. The simulation results show that the proposed ejector can work in a wide power range of 17.90–84.00 kW within a suitable supply hydrogen pressure range of 4–7 bar. More importantly, the ejector can not only maintain a recirculation ratio above 0.9 in the wide output power range but a high recirculation ratio greater than 2.0 in the low power output. The proposed ejector broadens the working range of a single ejector used in the PEMFC system, which significantly promotes the development of fuel cell being widely adopted in automobiles.     

Efficient fault diagnosis method of PEMFC thermal management system for various current densities

The temperature of a fuel cell has a considerable impact on the saturation of a membrane, electrochemical reaction speed, and durability. So thermal management is considered one of the critical issues in polymer electrolyte membrane fuel cells. Therefore, the reliability of the thermal management system is also crucial for the performance and durability of a fuel cell system. In this work, a methodology for component-level fault diagnosis of polymer electrolyte membrane fuel cell thermal management system for various current densities is proposed. Specifically, this study suggests fault diagnosis using limited data, based on an experimental approach. Normal and five component-level fault states are diagnosed with a support vector machine model using temperature, pressure, and fan control signal data. The effects of training data at different operating current densities on fault diagnosis are analyzed. The effects of data preprocessing method are investigated, and the cause of misdiagnosis is analyzed. On this basis, diagnosis results show that the proposed methodology can realize efficient component-level fault diagnosis using limited data. The diagnosis accuracy is over 92% when the residual basis scaling method is used, and data at the highest operating current density is used to train the support vector machine.     

A hybrid fuel cell system integrated with methanol steam reformer and methanation reactor

In this paper, a hybrid fuel cell system integrated with methanol steam reformer and methanation reactor is demonstrated. Methanol steam reformer employed in this system is to produce hydrogen-rich reformate in connection with a methanation reactor to reduce the carbon monoxide content effectively, and the reformate gas is sent into a low-temperature polymer electrolyte fuel cell for direct electric power generation. The optimum conditions (temperature, water to methanol ratio, and space velocity) for methanol steam reforming (MSR) reaction and methanation (MET) reaction are verified by experiments. A comparison between pure hydrogen, reformate surrogate, and actual reformate is performed. The results show that the power density of this hybrid system achieves 245.2 mW/cm² while it achieves 268.8 mW/cm² when employing pure hydrogen as the fuel. An alternative novel method to solve the problem of hydrogen storage and transportation is provided and the in-situ hydrogen production and utilizing through low-temperature fuel cell system is realized, which is helpful to accelerate the commercialization process of the fuel cell.